Avoiding Trouble

. . " a group of lines, hoses or wires. Don't be lulled into thinking you can remember where everything goes-you won't. If you hook up vacuum or fuel lines incorrectly, the vehicle may run poorly, if at all. If you hook up electrical wiring incorrectly, you may instantly learn a very expensive lesson.

You don't need to know the official or engineering name for each hose or line. A piece of masking tape on the hose and a piece on its fitting will allow you to assign your own label such as the letter A or a short name. As long as you remember your own code, the lines can be reconnected by matching similar letters or names. Do remember that tape will dissolve in gasoline or other fluids; if a component is to be washed or cleaned, use another method of identification. A permanent felt-tipped marker or a metal scribe can be very handy for marking metal parts. Remove any tape or paper labels after assembly.

Pay attention to the instructions provided. There are 3 common mistakes in mechanical work:

Incorrect order of assembly, disassembly or adjustment. When taking something apart or putting it together, performing steps in the wrong order usually just costs you extra time; however, it CAN break something. Read the entire procedure before beginning disassembly. Perform everything in the order in which the instructions say you should, even if you can't immediately see a reason for it. When you're taking apart something that is very intricate, you might want to draw a picture of how it looks when assembled at one point in order to make sure you get everything back in its proper position. We will supply exploded views whenever possible. When making adjustments, perform them in the proper order. One adjustment possibly will affect another.

Overtorquing (or undertorquing). While it is more common for overtorquing to cause damage, undertorquing may allow a fastener to vibrate loose causing serious damage. Especially when dealing with aluminum parts, pay attention to torque specifications and utilize a torque wrench in assembly. If a torque figure is not available, remember that if you are using the right tool to perform the job, you will probably not have to strain yourself to get a fastener tight enough. The pitch of most threads is so slight that the tension you put on the wrench will be multiplied many times in actual force on what you are tightening. A good example of how critical torque is can be seen in the case of spark plug installation, especially where you are putting the plug into an aluminum cylinder head. Too little torque can fail to crush the gasket, causing leakage of combustion gases and consequent overheating of the plug and engine parts. Too much torque can damage the threads or distort the plug, changing the spark gap.

There are many commercial products available for ensuring that fasteners won't come loose, even if they are not torqued just right (a very common brand is Loctite®). If you're worried about getting something together tight enough to hold, but loose enough to avoid mechanical damage during assembly, one of these products might offer substantial insurance. Before choosing a threadlocking compound, read the label on the package and make sure the product is compatible with the materials, fluids, etc. involved.

Crossthreading. This occurs when a part such as a bolt is screwed into a nut or casting at the wrong angle and forced. Crossthreading is more likely to occur if access is difficult. It helps to clean and lubricate fasteners, then to start threading the bolt, spark plug, etc. with your fingers. If you encounter resistance, unscrew the part and start over again at a different angle until it can be inserted and turned several times without much effort. Keep in mind that many parts, especially spark plugs, have tapered threads, so that gentle turning will automatically bring the part you're threading to the proper angle. Don't put a wrench on the part until it's been tightened a couple of turns by hand. If you suddenly encounter resistance, and the part has not seated fully, don't force it. Pull it back out to make sure it's clean and threading properly.

Be sure to take your time and be patient, and always plan ahead. Allow yourself ample time to perform repairs and maintenance. You may find maintaining your car a satisfying and enjoyable experience.